Stator assembly with magmate holder

ABSTRACT

Disclosed therein is a stator assembly, which includes a circular base part and a stator core having a plurality of teeth radially formed on an outer face of the base part and respectively having a tooth end portion. The stator assembly further includes: a magmate holder including a base plate, at least one inner leg and at least one outer leg formed at a lower portion of the base plate, and a power connector part formed on an upper portion of the base plate and having a joining projection formed at one side thereof; and a sensor cover including a body part and a hook formed on a lower portion of the body part and being joined with the joining projection.

TECHNICAL FIELD

The present invention relates to a stator assembly of a motor, and moreparticularly, to an improved stator assembly of a motor, which is easyto manufacture and can reduce manufacturing costs.

BACKGROUND ART

In general, a motor includes a stator and a rotor. When AC voltage isapplied to a coil wound on the stator, the rotor rotates by a rotationalmagnetic field, and the rotation of the rotor causes a rotation of aload applied to a rotor shaft. For instance, in the case of drum washingmachines, a drum is connected to the rotor shaft to thereby rotate withthe rotor.

As described above, in order to supply electricity to the motor or toapply an electric current to the motor, the stator assembly of the motorincludes a connector connected with a coil wound on the stator. KoreanPatent No. 10-1013781 discloses a stator assembly, and FIG. 1 is anexploded perspective view of the stator assembly.

As shown in FIG. 1, the stator assembly according to the prior artincludes a stator core 100, and upper and lower insulators 210 and 220respectively covering upper and lower portions of the stator core 100.The stator core 100 includes a circular base part 110, which is acentral part of the stator core 100, and teeth 120 radially formed on anouter face of the base part. Each of the teeth 120 includes a tooth endportion 125 formed at the end portion opposed to the base part and has aT-shaped cross section. A coil is wound on each of the teeth 120 in astate where the upper and lower insulators 210 and 220 are joinedtogether.

At an upper portion inside the upper insulator, the upper insulator 210includes a tap terminal 211 for a power terminal, which is a connectorfor connecting a power line, and another tap terminal 212 for connectinga common terminal (neutral point) of each phase. A sensor cover 215includes a hall sensor (not shown) mounted therein, and a tap connectionpart 216 connected to the tap terminal 211 for the power terminal and apower terminal part 217 for connecting electricity are formed in anoutward direction opposed to the tap connection part 216. The tapconnection part 216 and the power terminal part 217 are connected by alead wire (not shown) disposed inside the sensor cover.

According to such a structure of the stator assembly of the prior art,the upper insulator 210 and the lower insulator 220 are made from resinmolding, and hence, a great deal of resin moldings are used, and a sizeof the sensor cover 215 is increased because the tap terminal 211 forthe power terminal and the tap terminal 212 for the common terminal areformed inside the upper portion of the upper insulator 210, namely,formed more inside than the base part 110.

Accordingly, in order to solve the above problems, the inventors of thepresent invention introduce a new structure to join the sensor cover ina state where the surface of the stator core is insulated by powdercoating without the structure that the entire of the stator core isinsulated by the insulator, so as to reduce an amount of resin molding,simplify the manufacturing process and reduce manufacturing costs.

DISCLOSURE OF INVENTION Technical Problem

Accordingly, the present invention has been made in an effort to solvethe above-mentioned problems occurring in the prior arts, and it is anobject of the present invention to provide a stator assembly of a newstructure, in which an insulator covering the entire of the upperportion and the lower portion is not applied to a stator core.

It is another object of the present invention to provide a statorassembly with a magmate holder for joining a sensor cover and a statorcore together.

The foregoing and other objects of the present invention will beachieved and apparent from the following description, the appendingclaims and the accompanying drawings.

Solution to Problem

To achieve the above objects, the present invention provides a statorassembly, which includes a circular base part and a stator core having aplurality of teeth radially formed on an outer face of the base part andrespectively having a tooth end portion, including: a magmate holderincluding a base plate, at least one inner leg and at least one outerleg formed at a lower portion of the base plate, and a power connectorpart formed on an upper portion of the base plate and having a joiningprojection formed at one side thereof; and a sensor cover including abody part and a hook formed on a lower portion of the body part andbeing joined with the joining projection.

The sensor cover includes a sensor part disposed at one side of the bodypart thereof, and the sensor part includes at least one fixed leg, whichis formed at a position corresponding to the tooth end portion and has atooth end insertion hole formed at a lower end portion of one side ofthe fixed leg.

A stopper is formed on the upper end of the tooth end insertion hole.

The body part includes a bolt insertion hole formed at one side thereof,and a bolt inserted into the bolt insertion hole is inserted and fixedinto a bolt insertion hole formed in the base plate of the magmateholder.

The stator core includes an insulation coating layer formed on the outersurface thereof.

A stator core according to the present invention includes a circularbase part and a stator core having a plurality of teeth radially formedon an outer face of the base part and respectively having a tooth endportion, and further includes a first coating layer formed on the entiresurface of the base part and the teeth and a second coating layer formedon the surface of the first coating layer.

Advantageous Effects of Invention

The stator assembly of a new structure according to the presentinvention can simplify the manufacturing process and reducemanufacturing costs.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an exploded perspective view of a stator assembly according toa prior art.

FIG. 2 is an exploded perspective view of a stator assembly according tothe present invention.

FIG. 3 is a partially enlarged perspective view of the stator assemblyaccording to the present invention.

FIG. 4 is an enlarged perspective view viewed from an A direction ofFIG. 3.

FIG. 5 is a side view viewed from a B direction of FIG. 3.

Description will now be made in detail of preferred embodiment of thepresent invention with reference to the attached drawings.

MODE FOR THE INVENTION

FIG. 2 is an exploded perspective view of a stator assembly according tothe present invention, FIG. 3 is a partially enlarged perspective viewof the stator assembly according to the present invention, and FIG. 4 isan enlarged perspective view viewed from an A direction of FIG. 3.

As shown in FIGS. 2 to 4, the stator assembly according to the presentinvention includes a stator core 100, a magmate holder 10, and a sensorcover 20.

The stator core 100 includes a circular base part 110, and a pluralityof teeth 120 radially formed on an outer face of the base part 110, andeach of the teeth 120 has a tooth end portion 125 formed at the endthereof in such a fashion that each of the teeth 120 have a T-shapedcross section. The teeth 120 are portions where a coil is not wound (notshown). The surface of each tooth 120 is preferably coated with adielectric material, and hence, the wound coil and the teeth areinsulated from each other. In other words, the entire surface of thestator core 100 is preferably insulated by powder coating of insulatingpowder. More preferably, the entire surface of the stator core 100 ofthe present invention is doubly coated with insulating layers. That is,the stator core 100 has a first coating layer (not shown) formed on thesurface of the stator core 100 and a second coating layer (not shown)formed on the surface of the first coating layer. It is good to form thefirst and second coating layers by powder coating, but the presentinvention is not limited by the above.

The magmate holder 10 is joined and fixed to the stator core 100 andserves to join the sensor cover 2. The sensor cover 20 is joined andfixed to the magmate holder 10 and the tooth end portions 125.

The magmate holder 10 includes a base plate 11 placed on an upperportion of the base part 110. The base plate 11 is equal to or a littlebit larger in width than the base part 110. It is preferable that lengthof the base plate 11 is three or four times the width of each of teeth120, but the present invention is not limited by the above. The baseplate 11 has at least one inner leg 14 and at least one outer leg 15extending downward. The inner leg 14 extends downward in such a way asto be joined to the inner face of the base part 110 of the stator core,and the outer leg 15 extends downward in such a way as to be joined tothe outer face of the base part 110 of the stator core. The inner leg 14and the outer leg 15 respectively have retaining means, such as hooks,formed at ends thereof, so that the magmate holder 10 can be simply andfirmly joined to the stator core.

A power connector part 12 for connecting a power line and a commonterminal part 13 for connecting a common terminal are connected to anupper portion of the base plate 11. The power connector part 12 includespower terminals 121, which connect coil end portions of each phase, asmany as needed according to phases. In FIG. 2, three power terminals 121are illustrated. The power connector part 12 has at least one joiningprojection 122, and the joining projection 122 is joined with a hook 22of the sensor cover 20 to serve to fix the sensor cover 20. Moreover, inorder to more firmly fix the sensor cover 20, a protrusion 23 of thesensor cover 20 is inserted and fixed into a joining hole 123 formed atone side of the power connector part 12. Furthermore, in order toenhance the joining force of the sensor cover 20, a bolt joining portion124 is formed on the upper portion of the base plate. A bolt insertionhole 24 in which a bolt is inserted is formed in the sensor cover 20 insuch a way as to be correspond to the bolt joining portion 124.

The sensor cover 20 includes a body part 21 and a sensor part 25 formedat one side of the body part 21. The sensor cover 20 and the magmateholder 10 are joined together by a hook 22 protruding downwardly fromthe body part 21 of the sensor cover 20, and the sensor cover 20 and thestator core 100 are joined together by a fixed leg 26 formed at a lowerportion of the sensor cover 25.

The body part 21 of the sensor cover 20 joins the sensor cover 20 andthe magmate holder 10 together and has at least one lead wire (notshown) for connecting the power connector part 12 of the magmate holder10 with a power connection part 21 a for electric connection. Width ofthe body part 21 is as long as a distance ranging from the tooth endportion 125 to the inner face of the base part 110. In the statorassembly according to the prior art, because the tap terminal for thepower terminal is located more inside than inside the base part 110, thesensor cover of the stator assembly according to the prior art is widerthan that of the present invention. Accordingly, the stator assemblyaccording to the present invention can reduce manufacturing costsbecause the length of the lead wire for connecting the power connectionpart 21 a and the power connector part 12 with each other and amount ofresin molding used for the sensor cover are reduced.

At least one hook 22 protruding downward is formed at the lower portionof the body part 21, namely, at a position corresponding to the joiningprojection 122 of the power connector part 12, and the number of thehooks 22 corresponds to the number of the joining projections 122 of themagmate holder 10. The hook 22 and the joining projection 122 areengaged and fixed to each other, but the forms of the hook 22 and thejoining projection 122 are not restricted to the forms illustrated inFIG. 2.

A protrusion 23, which protrudes downward, is formed at the lowerportion of the body part 21, namely, at a position corresponding to thejoining hole 123 of the power connector part 12. The protrusion 23 isinserted into the joining hole 123 to make the sensor cover be morefirmly joined. The terms, joining hole 123 and protrusion 23 in thepresent invention may be switched each other in spite of their outermeanings. In other words, the joining hole 123 may have the shape of theprotrusion and the protrusion 23 may have the shape of the joining hole123.

A bolt insertion hole 24 is formed at the upper portion of the body part21, namely at a position corresponding to the bolt joining portion 124of the power connector part 12. A bolt 30 is inserted into the boltinsertion hole 24 and joined to the bolt joining portion 124, so as toenhance a joining force of the sensor cover 20.

The sensor cover 20 includes a hall sensor (not shown) mounted insidethe sensor part 25 and at least one fixed leg 26 formed on the lowerportion of the sensor cover 20. The fixed leg 26 is joined to the toothend portion 125 of the stator core 100, and referring to FIG. 5, thestructure of the sensor cover 20 will be described in detail.

FIG. 5 is a side view of the sensor cover 20 viewed from a B directionof FIG. 3.

As shown in FIG. 5, the sensor part 25 of the sensor cover 20 has atleast one fixed leg 26 formed on a lower portion of the sensor part 25.The fixed leg 26 is joined to the tooth end portion 125 and includes atooth end insertion hole 26 a, which is formed at one side or both sidesof the lower portion of the fixed leg 26, and, to which the tooth endportion 125 is inserted. Additionally, a stopper 26 b is formed at anend portion of an upper portion of the tooth end insertion hole 26 a toprevent the tooth end portion from being inserted more. Through such astructure of the fixed leg 26, the fixed leg 26 can support the outerpart of the sensor cover 20.

While the present invention has been particularly shown and describedwith reference to exemplary embodiment thereof, it will be understood bythose of ordinary skill in the art that various changes in form anddetails may be made therein without departing from the spirit and scopeof the present invention described in claims.

EXPLANATION OF ESSENTIAL REFERENCE NUMERALS IN DRAWINGS

-   10: magmate holder 11: base plate-   12: power connector part 13: common terminal part-   14: inner leg 15: outer leg-   20: sensor cover 21: body part-   21 a: power connection part 22: hook-   23: protrusion 24: bolt insertion hole-   25: sensor part 26: fixed leg-   26 a: tooth end insertion hole-   26 b: stopper 30: bolt-   100: stator core 110: base part-   120: teeth 121: power terminal-   122: joining projection 123: joining hole-   124: bolt joining portion-   125: tooth end portion 210: upper insulator-   211: tap terminal for power terminal-   212: tap terminal for common terminal-   215: sensor cover 216: tap connection part-   220: lower insulator

1. A stator assembly, which includes a circular base part and a statorcore having a plurality of teeth radially formed on an outer face of thebase part and respectively having a tooth end portion, the statorassembly comprising: a magmate holder including a base plate, at leastone inner leg and at least one outer leg formed at a lower portion ofthe base plate, and a power connector part formed on an upper portion ofthe base plate and having a joining projection formed at one sidethereof; and a sensor cover including a body part and a hook formed on alower portion of the body part and being joined with the joiningprojection.
 2. The stator assembly according to claim 1, wherein thesensor cover comprises a sensor part disposed at one side of the bodypart thereof and the sensor part comprises at least one fixed leg, whichis formed at a position corresponding to the tooth end portion and has atooth end insertion hole formed at a lower end portion of one side ofthe fixed leg.
 3. The stator assembly according to claim 2, wherein astopper is formed on the upper end of the tooth end insertion hole. 4.The stator assembly according to claim 1, wherein the body partcomprises a bolt insertion hole formed at one side thereof, and a boltinserted into the bolt insertion hole is inserted and fixed into a boltinsertion hole formed in the base plate of the magmate holder.
 5. Thestator assembly according to claim 1, wherein the stator core comprisesan insulation coating layer formed on the outer surface thereof.
 6. Astator core, which includes a circular base part and a stator corehaving a plurality of teeth radially formed on an outer face of the basepart and respectively having a tooth end portion, the stator corecomprising: a first coating layer formed on the entire surface of thebase part and the teeth; and a second coating layer formed on thesurface of the first coating layer.